MOSAIC OCTOPLUS HORIZONTAL INVERTER MULTIZONE CLIMATIZATION SYSTEM EWCIBA - Models: 16-i 20-i 25-i Cooling Capacities: from 15.8 kw to 24.3 kw Heating Capacities: from 18.1 kw to 27.9 kw Installation, Operation & Maintenance Manual 09.18 207733 Rev.103
Thank you for trusting the Hitecsa Products. Our company has been offering the market an extended range of specialized units for air conditioning and cooling installations for over 35 years. Our approach is based on efficiency, adaptability, usability and practical solutions. This has been the hallmark of our product catalogue. The versatility of our factory allows us to contribute solutions, almost tailored to each project s specifications, in search of a solution to every problem that arises in design and implementation of air conditioning installations. From all of us at Hiplus Aire Acondicionado, once again, thank you very much.
MOSAIC - OCTOPLUS INDEX INTRODUCTION... 5 CONTENTS... 5 REGULATIONS AND CERTIFICATIONS... 6 SAFETY PRECAUTIONS... 7 SYSTEM DESCRIPTION... 9 NOMENCLATURE... 10 RANGE... 10 TECHNICAL DATA... 11 OCTOPLUS CENTRAL UNIT EWCIBA... 11 INDOOR UNITS... 13 FCW OCT / FCCW OCT... 13 INDOOR UNIT BSW-OCT... 15 FK ZEN-OCT... 16 RECEPTION... 18 INSPECTION AT RECEPTION... 18 RIGGING... 18 STORAGE... 18 INSTALLATION... 19 EWCIBA DIMENSIONS AND WEIGHT... 19 Model 16-i... 19 Model 20-i 25-i... 20 FK ZEN-OCT models 62 / 65... 21 FK ZEN BIG-OCT 72 model... 21 FCCW-OCT models... 22 FCW-OCT models... 23 DIMENSIONS... 24 FCW and FCCW connections... 24 DIMENSIONS... 25 BSW-OCT MODELS... 25 INSTALLATION LOCATION... 26 UNIT SETTLEMENT... 26 On Floor... 26 Suspended from the Ceiling... 26 SERVICE AREA (OCTOPLUS)... 29 Model 16-i... 29 Models 20-i 25-i... 29 WATER DRAIN... 30 AIR DUCTS... 31 WATER PIPELINES... 32 Preliminary Information... 32 Components... 32 Risk of Frost... 32 Glycol Additions... 33 3 09.18 207733 Rev.103
Hydraulic Connections... 33 ELECTRICAL INSTALLATION CENTRAL UNIT... 33 Electrical Data... 33 Electrical Diagram (OCTOPLUS)... 34 Controller... 36 INSTALLATION AND CONFIGURATION OF INDOOR UNITS... 36 Configuration of Indoor Units in the Network... 36 Addressing Indoor Units... 37 Connection between Indoor Units and the Thermostat... 37 CONFIGURATION OF INDOOR UNITS IN THE OCTOPLUS SYSTEM... 38 REFRIGERATION DIAGRAMS... 39 Models from 16-i to 25-i... 39 OPERATION... 40 START UP... 40 ELECTRIC SYSTEM... 40 HYDRONIC SYSTEM... 40 VENTILATION SYSTEM... 40 OUTDOOR FAN TRANSMISSION ADJUSTMENT... 41 OPERATING LIMITS... 42 THERMOSTAT AND CONTROL... 43 Mini-pGD or pgd1 Thermostat... 43 Severe Alarm Reset... 43 Operating Mode Setting... 44 Alarms OCTOPLUS Unit... 46 INDOOR UNITS... 49 Alarms in FCW-OCT / FCCW-OCT / BSW-OCT Boards... 49 Alarms in CASSETTE Board... 50 OPERATION... 51 EC MOTOR FANS:... 51 Trouble shooting... 51 Status Out with flash code... 52 Rotation caused by an air flow in false direction... 52 MAINTENANCE... 53 POSITION OF THE ELEMENTS OF FKZEN-OCT... 53 CONSERVATION AND CLEANING... 54 CLEANING THE AIR FILTER... 54 WATER QUALITY... 55 MAINTENANCE WITH EC MOTOR FAN... 55 EC MOTOR FAN MAINTENANCE AND REPAIRS... 55 EC MOTOR FAN CLEANING... 56 LUBRICANT... 56 REFRIGERANT CHARGE... 57 APPENDIX: SAFETY DATA R410A... 58 4 09.18 207733 Rev.103
INTRODUCTION CONTENTS Purpose of the Manual Preservation Manual This manual and the instruction documents of refrigeration lines, electrical diagrams and any other attached documents, have been written to allow a correct installation, commissioning and maintenance of the unit. Therefore it is essential to read the instructions with due attention. Verify that all the necessary information for the correct installation of the system is included in the manuals supplied with this unit and/or the rest of the indoor units, accessories, etc. Otherwise, the manufacturer declines any responsibility for any damage to people, animals or materials, as a result of improper use of the unit and/or failure to observe these instructions. This manual and the electric diagram of the unit must be retained and remain available to the operator for any further consultation. Updating the Data The continuous improvement in design and performance to which we are committed gives us the right to modify the specifications of our products without prior notice. Electrical Network Check that electrical network features are in accordance to data shown in the data nameplate of the unit. Local Safety Regulations Observe and analyse all possible causes of accidents that may arise in the place or places of installation of the units, check means and tools to use, etc. It is not possible to anticipate each and every one of the potential circumstances of danger in this manual. Respect the local security standards during installation. Principles of Security on Installation The unit is designed and built in a way that does not pose a risk to the health and safety of people. Appropriate solutions for the project have been adopted to eliminate the possible causes of risk in the installation. Packaging and Replacement of Equipment Utilization The material of the package (plastic bags, insulating materials, nails, etc.) is a potential source of danger. Consequently, it should be kept out of the reach of children and properly recycled according to the valid local safety regulations. This product should not be mixed with household waste at the end of its life. Due to the refrigerant, oil and other components contained in this product, it must be dismantled by professional installers in accordance with current regulations. The unit shall be used only for the reason it has been conceived. Any other use does not imply any kind of compromise or link for the manufacturer. Incorrect Operation In case of breakdowns or operation faults, turn the unit off. 5 09.18 207733 Rev.103
INTRODUCTION CONTENTS Periodic Inspections and Maintenance Repairs Modifications Carry out periodic inspections to detect possible damaged or broken parts. If they are not repaired it could cause damage to people or stuff. Before executing any maintenance operation, cut off the unit power supply. All operations must be carried out in accordance with local safety regulations. The reparations should be always and exclusively realized for trained personal authorized by the manufacturer using original spares. The safeties of the unit could be affected due to the failure to comply with these warnings. The manufacturer will not respond to the warranty and to the possible damages of the unit in case of electrical and/or mechanical modifications. The unauthorized manipulation, reparation or modification of the unit will automatically invalidate the warranty. Refrigerant This product is hermetically sealed and contains R-410A which is a HFC fluorinated greenhouse gas. REGULATIONS AND CERTIFICATIONS ISO 9001:2008 CERTIFICATION: HILPUS AIRE ACONDICIONADO S.L., trying always to find the customer satisfaction, has obtained the ISO 9001:2008 Quality System referred to its production activity. This will results in a continuous determination to improve quality and reliability of all our products; commercial activities, design, raw materials, production and after-sales service, are the means to reach our goal. CE MARKING: Our machines have got the CE mark, in conformity with the essential requirements of the applicable EC directives and their last modifications as well as with the national legislation of each country. CERTIFICACION EUROVENT: HITECSA participates in the EUROVENT Certification program. Check certified products on the web. 6 09.18 207733 Rev.103
INTRODUCTION SAFETY PRECAUTIONS DANGER Do not touch or adjust the safety elements inside of any unit of the system. During repairing operations use only original spare parts and install them properly in the same position where old parts were placed. The installation and maintenance of air conditioning equipment could be dangerous because the system is under pressure, some of its elements have high temperatures and include electrical components. Do not install the unit in explosive atmosphere. Before starting any installation, service or maintenance operation, turn off the main power switch in order to avoid electrical shock that may cause personal damages. To open the electrical panel and access the inside of the machine it is MANDATORY to disconnect the power supply hose from the machine. It MUST BE FREE OF TENSION for this operation. It is generally forbidden to carry out work on electrical live parts. Protection class of the device when it is complete opened is IP00! Be careful, do not touch hazardous voltages directly. Check the safe isolation from the supply using a two-pole voltage detector. Even after disconnecting the main voltage, life-threatening charges can appear between the protective ground PE and the main connection. EC FAN: - When the motor runs independently due to air flowing through or if it continues to run down after being turned off, dangerous voltages of over 50 V can arise on the motor internal connections through operation of the generator. - The protective earth is conducting high discharge currents (dependent on the switching frequency, current source voltage and motor capacity). Earthing in compliance with EN specifications shall therefore be observed even for testing and trial conditions (EN 50 178, Art. 5.2.11). Without earthing, dangerous voltages can be present on the motor housing. - Through use of capacitors, danger of death exists even after switching off de device in case of direct contact with conductive parts or with parts that carry voltage due to fault condition. It is only allowed remove or open the housing of the controller when the power supply cable is disconnected and after a waiting time of 3 minutes. 7 09.18 207733 Rev.103
INTRODUCTION SAFETY PRECAUTIONS ATTENTION! Only qualified and trained service staff (technical service) must make the installation, commissioning and carry out maintenance works. Unqualified personnel will only carry out basic tasks such as cleaning and replacement of filters, or filter cleaning (excluding refrigerant filters), etc. Prevent access to children so that they cannot play with the appliances. In every visit, all precautions must be taken into account: those recommended in the installation, operation and maintenance instructions, as well as the ones indicated in labels of the unit. Do not forget to strictly follow any other safety precautions. DO NOT introduce objects into the air inlets or outlets that can be drawn into the fan, people, etc. Use safety glasses, work gloves and any other safety accessory necessary. EC FAN: - The fan / motor may switch on and off automatically for functional reasons. - After power failure or main disconnection an automatic restart of the fan takes places after voltage return! - Wait for the fan to come to a complete standstill before approaching it! - In the AC external rotor motor the external rotor turns during operation! This product contains fluorinated greenhouse gases, its leakage can cause displacement of air and cause insufficient oxygen to breath. Must follow all safety recommendations. WARNING! The responsibility of all personal and material damages caused by an unplanned or wrong use will be born by the person or operating Company of the unit, and not by the manufacturer. 8 09.18 207733 Rev.103
INTRODUCTION SYSTEM DESCRIPTION The MOSAIC-OCTOPLUS range is designed for offices, shops and private homes where other compact or split conventional units cannot be used due to legal and/or functional reasons. Thanks to its low silhouette and centrifugal/radial unit the main applications are banks, shops and offices where it can be installed in false ceilings or technical rooms. The system comprises a central unit with electronic control of the compressor, expansion valve and circulating water pump, which makes unnecessary the existence of buffer tanks. Higher Performance: Full-inverter technology. Without buffer tank, without risk of heavy water losses. Minimal Environmental Impact: Hydronic System, no need to use refrigerants during installation, the minimum use of refrigerant is charged and checked in the central unit. Increased Comfort: Possibility of incorporating several indoor units (up to 8 units) with different power for each of them, greater stability during defrosting without the cold air dart which is a characteristic of direct expansion. Higher speed when changing the operation mode because the buffer tank is not necessary, typical of normal hydronic systems. The Main Unit is composed of: Low silhouette furniture for false ceiling or technical room. Inverter scroll compressor with BLDC motor and rotor with permanent magnets, thus lacking magnetization current losses in the rotor itself. Radial type external fan with integrated EC motor for high pressure loss in air ducts or double suction centrifugal fan driven by a three-phase motor powered by a frequency converter. External exchanger built with hydrophilic aluminium fins and copper tube mechanically expanded with high performance. Internal high-performance stainless steel welded plate heat exchanger. Suction accumulator to protect the equipment from possible liquid hammer and ensuring the return of oil to the compressor. Special copper refrigeration tube, dehydrated, with built-in filter drier. Liquid tank to compensate the charge variations in the heat exchangers as a result of the change between COLD- HEAT modes. Electronic expansion valve to achieve a high efficiency of the machine and to ensure the reheating of the evaporated gas before its arrival to the compressor. Three-phase water pump powered by a frequency converter as well as an expansion vessel to absorb the volume increase produced as a result of the water expansion in heating mode and to return that volume when water cools. Central display with indication of the status of the system as well as any possible incidents that may arise. The Indoor Units are characterized by: Infrared remote control or wall control. 3-speed motor or EC motor. Possibility to include integrated electrical heaters. Motorized louvers that take advantage of the coanda effect in cooling mode and an anti-stratification effect in heating mode for cassette internal units. 2-way valves incorporated as standard. Possibility of internal units with centrifugal motor for application of ducts. 9 09.18 207733 Rev.103
INTRODUCTION NOMENCLATURE OCTOPLUS series EWCIBA E W C I B A - 2 5 - i Water Chiller Centrifugal Fan Inverter Heat Pump R-410A Inverter Power (kw) RANGE OUTDOOR UNIT INDOOR UNITS Cassette Type Vertical FK ZEN OCT (2.8 and 5.4 kw) FK ZEN BIG OCT (9,5 kw) Horizontal FCCW OCT (1.7 to 8.7 kw) Medium Pressure EWCIBA 16-i 20-i 25-i FCW OCT (2.4 and 4.6 kw) BSW OCT (5.9 to 13.1 kw) 10 09.18 207733 Rev.103
TECHNICAL DATA OCTOPLUS CENTRAL UNIT EWCIBA COOLING CAPACITY EWCIBA 16-i 20-i 25-i Cooling Capacity (1) kw 15,80 19,90 24,30 Total Power Input in Cooling Mode (3) kw 5,83 7,03 9,00 EER 2,71 2,83 2,70 Evaporator Water Flow m 3 /h 2,6 3,3 4,1 Evaporator Pressure Drop kpa 240 215 200 Energy Class A A A HEATING CAPACITY Heating Capacity (2) kw 18,10 22,70 27,90 Total Power Input in Heating Mode (3) kw 6,18 7,75 9,55 COP 2,93 2,93 2,92 Evaporator Water Flow m 3 /h 3,1 3,9 4,8 Evaporator Pressure Drop kpa 225 195 175 Energy Class B B B Cold / Heat Expansion Device REFRIGERANT CIRCUIT Electronic Valve Number of Circuits Units 1 Type R-410A Global Warming Potential (GWP) (4) 2088 Refrigerant Charge kg 5,00 6,80 7,30 Type COMPRESSORS Scroll BLDCM Number of Compressors Units 1 Operating Range over Rated Value Min/Max 18 % / 110 % Maximum Current per Compressor A 16,2 19,7 24,9 Oil Type Oil Volume L 1,7 1,7 2,3 OUTDOOR HEAT EXCHANGER FV50S Evacuation of Condensates Ø Tube 3/4" Type CENTRIFUGAL OUTDOOR FAN Centrifugal Number of Fans Units 1 Power input kw 1,5 1,5 2,2 Rated Air Flow m 3 /h 6.000 8.000 9.000 Static Pressure (Maximum) Pa 120 Sound Level in Discharge dba 87 91 92 (1) COOLING MODE: Calculated according to standard UNE-EN-14511-2013, Outdoor temperature 35ºC, Water inlet temperature 12ºC, Water outlet temperature 7ºC. (2) HEATING MODE: Calculated according to standard UNE-EN-14511-2013, Outdoor temperature 7ºC D.B. / 6ºC W.B., Inlet temperature 40ºC, Water outlet temperature 45ºC. (3) TOTAL POWER INPUT: Power input by the equipment in Cold or Heat conditions indicated above according to UNE-EN-14511-2: 2013 standard. (4) GWP: Global warming potential (climatic) of 1 kg of greenhouse gas relative to 1 kg of CO2, calculated in terms of 100-year warming potential. 11 09.18 207733 Rev.103
TECHNICAL DATA OCTOPLUS CENTRAL UNIT EWCIBA EWCIBA 16-i 20-i 25-i EC OUTDOOR FAN Type Radial Number of Fans Units 1 Features: Fan Diameter mm 400 450 450 Power Input mm 2,4 3,6 3,6 Rated Air Flow m³/ h 6.000 8.000 9.000 Static Pressure (Rated) Pa 120 Static Pressure (Maximum) Pa 450 800 590 Sound Level in Discharge (Rated Pressure) dba 85 88 91 INDOOR HEAT EXCHANGER Type Plates (Water Refrigerant) Quantity Units 1 Minimum Water Flow m³/ h 1,0 1.0 1.0 Minimum Water Volume L 2,3 2,9 3,4 Anti-Ice Resistance W 50 CIRCULATING PUMP Quantity Units 1 Maximum Available Pressure kpa 240 215 200 WATER CIRCUIT Expansion Tank L 11 Buffer Tank No Water Entrance/Exit: Connection Type SLOTTED Victaulic type Connection Diameter ( ) 1 1/2 '' ELECTRIC SPECIFICATIONS Power Supply V / ~ / Hz 400 / 3+N / 50 Maximum Current A 21,2 25,8 31,2 Starting Current (AC) A Soft Start (without starting spikes) Differential Switch ma 300 SOUND LEVEL Sound Power with EC Fan (Surround) db(a) 85 86 88 Sound Pressure with EC Fan (Surrounding 5m) db(a) 63 64 66 Sound Power with Centrifugal Fan (Surround) db(a) 87 88 90 Sound Pressure with Centrifugal Fan (Surrounding 5m) db(a) 61 62 64 DIMENSIONS AND WEIGHT Large mm 1.880 1.880 1.880 Width mm 1.534 1.810 1.810 Height mm 637 675 675 Net Weight kg 380 414 439 12 09.18 207733 Rev.103
TECHNICAL DATA INDOOR UNITS FCW OCT / FCCW OCT Total Cooling Capacity Sensitive Cooling Capacity Water Flow Water Pressure Loss Heating Capacity Water Flow Water Pressure Loss Heating Capacity Water Flow Water Pressure Loss MODELS FCW-OCT (Horizontal) FCCW-OCT (Vertical with Cabinet) 30 60 30 60 80 110 AVAILABLE PRESSURE 20 Pa* 0 Pa COOLING CAPACITY (1) HEATING CAPACITY (2) HEATING CAPACITY (3) * For a duct with a pressure drop of 20 Pa at maximum speed. kw Max. 2.38 4.18 2.13 3.45 4.95 9.69 kw Med. 2.14 3.52 1.86 3.07 4.12 8.69 kw Min. 1.81 2.72 1.42 2.46 3.02 7.07 kw Max. 1.66 2.91 1.62 2.74 3.45 7.39 kw Med. 1.47 2.42 1.44 2.33 2.83 6.74 kw Min. 1.24 1.86 1.10 1.90 2.06 5.39 l/h Max. 419 735 534 871 1380 2041 l/h Med. 377 619 479 727 1226 1676 l/h Min. 319 479 377 534 1117 1330 kpa Max. 10 16,5 16,2 23,0 27,0 33,0 kpa Med. 8,1 11,8 13,0 16,5 22,0 23,0 kpa Min. 5,8 7,2 8,1 8,9 19,0 15,0 kw Max. 2.35 4.23 2.15 3.76 5.04 10,.69 kw Med. 2.09 3.56 1.94 3.31 4.18 9.51 kw Min. 1.73 2.74 1.58 2.61 3.08 7.59 l/h Max. 410 749 531 887 1456 2249 l/h Med. 365 626 474 728 1308 1697 l/h Min. 302 477 371 536 1187 1342 kpa Max. 8,7 14,5 13,7 20,0 26,0 33,5 kpa Med. 7,1 10,3 11,2 13,9 22,0 20,1 kpa Min. 5,1 6,2 7,3 7,7 18,0 13,0 kw Max. 2.83 5.00 2.57 4.48 6.03 12.71 kw Med. 2.52 4.17 2.33 3.94 5.02 11.32 kw Min. 2.08 3.16 1.88 3.12 3.69,.37 l/h Max. 415 724 534 871 1380 2041 l/h Med. 369 604 479 727 1226 1676 l/h Min. 306 458 377 534 1117 1330 kpa Max. 8,7 13,6 13,5 19,6 23,1 27,5 kpa Med. 7 9,5 11,1 13,7 19,1 19,3 kpa Min. 5,1 5,5 7,3 7,5 15,8 12,5 (1) COOLING MODE: Water Inlet Temperature 7ºC - Water Outlet Temperature 12ºC - Air Inlet Temperature 27ºC D.B. / 19ºC W.B. (2) HEATING MODE: Air Temperature 20ºC - Water Inlet Temperature 45 / Water Outlet Temperature 40ºC (3) HEATING MODE: Air Temperature 20ºC - Water Inlet Temperature a 50ºC 13 09.18 207733 Rev.103
TECHNICAL DATA INDOOR UNITS FCW OCT / FCCW OCT Electric Heater Capacity Air Flow Sound Power Level Sound Pressure Level ADDITIONAL DATA MODELS FCW-OCT (Horizontal) FCCW-OCT (Vertical with Cabinet) 30 60 30 60 80 110 W - 2000 3000 2000 3000 3000 4000 A - 8.7 13.04 8.7 13.04 13.04 17.39 m³/h Max. 405 756 576 925 1373 2449 m³/h Med. 340 596 495 726 1106 1690 m³/h Min. 250 402 360 495 1025 1229 db(a) Max. 47 64 47 64 59 69 db(a) Med. 43 59 43 59 56 66 db(a) Min. 37 52 37 52 54 58 db(a) Max. 38 55 38 55 50 60 db(a) Med. 34 50 34 50 47 54 db(a) Min. 28 43 28 43 45 49 Indoor Water Volume l. - 1.61 2.93 1.61 2.93 3.28 4.04 ELECTRIC SPECIFICATIONS: CENTRIFUGAL FAN of VARIABLE SPEEDS Power Supply V / ~ / Hz - 230 / I / 50 230 / I / 50 Power Input Rated Current W Max. 59 131 59 131 148 251 W Med. 48 113 48 113 126 212 W Min. 33 91 33 91 117 180 A Max. 0.24 0.60 0.24 0.60 0.67 1.13 A Med. 0.20 0.51 0.20 0.51 0.58 0.99 A Min. 0.14 0.41 0.14 0.41 0.54 0.85 ELECTRIC SPECIFICATIONS: RADIAL FAN with EC MOTOR Power Supply V / ~ / Hz - 230 / I / 50 230 / I / 50 Power Input WATER CONNECTIONS W Max. - - - - 82 248 W Med. - - - - 49 124 W Min. - - - - 42 51 Water Inlet / Outlet battery Ø" - 3/4" 3/4" 3/4" 3/4" 3/4" 3/4" Water Inlet / Outlet (equip.w/tubes) Drainage of Condensates Ø mm - 20 20 20 20 20 20 DIMENSIONS AND WEIGHT Height mm - 220 220 480 585 607 607 Width mm - 1020 1220 1260 1460 1660 1960 Large mm - 470 575 225 225 257 257 Net Weight Kg - 27 35 27 35 46 57 14 09.18 207733 Rev.103
TECHNICAL DATA INDOOR UNIT BSW-OCT COOLING CAPACITY (1) MODELS 2 3 5 kw Max. 6.58 9.02 15.13 Total Cooling Capacity kw Med. 5.92 7.82 13.13 kw Min. 5.62 6.97 11.81 kw Max. 4.39 6.51 11.08 Sensitive Cooling Capacity kw Med. 4.28 5.58 8.65 kw Min. 4.05 4.93 8.48 Water Flow l/h Max. 1065 1590 2695 Water Pressure Loss kpa Max. 14.6 18.6 21.0 HEATING CAPACITY 45ºC (2) Kw Max. 6.57 9.63 16.84 Heating Capacity kw Med. 6.41 8.31 14.64 kw Min. 6.05 7.35 12.84 Water Flow l/h Max. 1144 1686 2934 Water Pressure Loss kpa Max. 13.8 17.0 20.2 HEATING CAPACITY 50ºC (3) kw Max. 7.83 11.56 20.03 Heating Capacity kw Med. 7.64 9.93 17.44 kw Min. 7.22 8.79 15.33 Water Flow l/h Max. 1065 1590 2695 Water Pressure Loss kpa Max. 11.9 15.2 17.1 ADDITIONAL DATA Electric Heater Capacity (option) W - 7.5/9.6 7.5/9.6 9.0/12.0 m³/h Max. 1039 1528 2806 Air Flow m³/h Med. 1007 1267 2349 m³/h Min. 939 1092 1997 Available Static Pressure Pa - 50 db(a) Max. 65 66 71 Sound Power Level db(a) Med. 64 60 66 db(a) Min. 64 57 62 Sound Pressure Level db(a) Med. 55 51 57 db(a) Max. 56 57 62 db(a) Min. 55 48 53 ELECTRIC SPECIFICATIONS Power Supply V / ~ / Hz - 230 / I / 50 W Max. 132 224 529 Power Input W Med. 126 195 461 W Min. 122 174 410 A Max. 0.64 1.08 2.56 Rated Current A Med. 0.61 0.94 2.23 A Min. 0.59 0.84 1.98 WATER CONNECTIONS Water Inlet / Outlet battery Ø" - 3/4" 3/4" 1" Water Inlet / Outlet (equip.w/tubes) Ø" - 3/4" 3/4" 1" Drainage of Condensates Ø mm - 20 20 20 DIMENSIONS AND WEIGHT Width mm C 1070 1270 1520 Width incl. accessories (4) mm - 1230 1430 1800 Large mm G 643 643 770 Height mm D 297 347 397 Net Weight kg - 38 49 72 (1) COOLING MODE: Water Inlet Temperature 7ºC - Water Outlet Temperature 12ºC - Air Inlet Temperature 27ºC D.B. / 19ºC W.B. (2) HEATING MODE: Air Temperature 20ºC - Water Inlet Temperature 45 ºC / 40ºC (3) HEATING MODE: Air Temperature 20ºC - Water Inlet Temperature 50ºC (4) ACCESSORIES: V2V, shut-off valve and regulation and condensates collection tray. 15 09.18 207733 Rev.103
TECHNICAL DATA INDOOR UNITS FK ZEN-OCT MODELS 62 65 BIG 72 COOLING CAPACITY (1) kw Max. 2.67 5.38 9.50 Total Cooling Capacity kw Med. 2.43 4.65 6.60 kw Min. 1.94 3.97 5.34 kw Max. 2.03 3.99 6.40 Sensitive Cooling Capacity kw Med. 1.81 3.35 4.34 kw Min. 1.42 2.78 3.46 l/h Max. 465 939 1641 Water Flow l/h Med. 424 812 1144 l/h Min. 338 691 923 kpa Max. 16.0 30.0 33.5 Water Pressure Loss kpa Med. 14.0 24.0 13.5 kpa Min. 10.0 18.0 8.5 HEATING CAPACITY 45ºC (2) kw Max. 2.62 5.42 8.61 Heating Capacity kw Med. 2.37 4.93 5.97 kw Min. 1.91 4.09 4.59 l/h Max. 456 943 1500 Water Flow l/h Med. 413 860 1039 l/h Min. 333 712 800 kpa Max. 15.5 29.6 25.0 Water Pressure Loss kpa Med. 12.5 25.7 10.8 kpa Min. 8.9 19.2 7.9 HEATING CAPACITY 50ºC (3) kw Max. 3.15 6.50 10.40 Heating Capacity kw Med. 2.85 5.90 7,20 kw Min. 2.30 4.90 5.55 l/h Max. 465 939 1641 Water Flow l/h Med. 424 812 1144 l/h Min. 338 691 923 kpa Max. 16.0 29.0 29.0 Water Pressure Loss kpa Med. 13.0 23.0 12.5 kpa Min. 9.0 18.0 10.0 (1) COOLING MODE: Water Inlet Temperature 7ºC - Water Outlet Temperature 12ºC - Air Inlet Temperature 27ºC D.B. / 19ºC W.B. (2) HEATING MODE: Air Temperature 20ºC - Water Inlet Temperature 45 ºC / Water Outlet Temperature 40ºC (3) HEATING MODE: Air Temperature 20ºC - Water Inlet Temperature a 50ºC 16 09.18 207733 Rev.103
TECHNICAL DATA INDOOR UNITS FK ZEN-OCT ADDITIONAL DATA MODELS 62 65 BIG 72 Electric Heater Capacity kw - 1.50 2.50 - Air Flow Sound Power Level m³/h Max. 398 760 1270 m³/h Med. 355 660 858 m³/h Min. 269 550 662 db(a) Max. 44 62 53 db(a) Med. 41 59 40 db(a) Min. 34 53 34 Sound Pressure Level db(a) Med. 32 50 31 db(a) Max. 35 53 44 db(a) Min. 25 44 25 ELECTRIC SPECIFICATIONS: CENTRIFUGAL FAN with VARIABLE SPEEDS Power Supply V / ~ / Hz - 230 / I / 50 Power Input W Max. 43 89 108 Rated Current A Max. 0.19 0.39 0.60 ELECTRIC SPECIFICATIONS: RADIAL FAN with EC MOTOR Power Input W Max. 11 65 89 Rated Current A Max. 0.11 0.47 - WATER CONNECTIONS Ø Water Inlet / Outlet " - ½ ¾ ¾ Ø Drainage of Condensates mm - 13.5 13.5 13.5 DIMENSIONS and UNIT WEIGHT High mm - 285 285 326 Large mm - 575 575 818 Width mm - 575 575 818 Net Weight kg - 21 24 45 DIMENSIONS and PANEL WEIGHT Height mm - 40 40 55 Width mm - 680 680 900 Depth mm - 680 680 900 Net Weight kg - 3 3 5 17 09.18 207733 Rev.103
RECEPTION INSPECTION AT RECEPTION It is advisable to examine the equipment carefully at the time of its reception. Check that the equipment has not been damaged during transport and it has been supplied complete with all parts specified in the order and/or with the options specified in the order. If this is not the case contact the transport company urgently (within 48h). Verify the correct voltage of the nameplate and make sure it is in accordance with local power supply. In case of any flaw or anomaly detected, please contact HITECSA. RIGGING Before moving the unit, make sure that all panels are well fixed. Raise and set down the equipment carefully. Do not tilt the unit more than 15 degrees during transportation. When lifting the unit, make sure that it is balanced and stable. Bear in mind that the heaviest part is where the compressor is installed. Always transport the unit in its original packaging to the place of installation. All the units come with a drawing of own hoist to each model, similar to the one that is presented below. STORAGE If the equipment is going to be stored before the installation, please follow the instructions below in order to avoid damages, corrosion or deterioration: Move it carefully. Do not place the machine in places exposed to ambient temperature above 50ºC and preferably keep the unit away from direct sunlight. The indoor units should be stored indoors and at a temperature not exceeding 40ºC. Avoid prolonged storage, before installation, water inlet, dust and objects in general due to invasion or biological, meteorological conditions and/or human intervention. The action of the sun can cause a very high temperature rise and consequently the pressure of the refrigerant reaches very high values too. In addition, water condensation will occur inside the machine or between the machine and the thermo-shrink plastic wrap (if present). Avoid placing other objects on top of the unit (unless it is done within the limits of the overlap planes indicated on the packaging). Minimum storage temperature: 5ºC. Maximum Relative Humidity: 90%. 18 09.18 207733 Rev.103
INSTALLATION EWCIBA DIMENSIONS AND WEIGHT Model 16-i EWCIBA CENTRE OF GRAVITY (cm) WEIGHT DISTRIBUTION (kg) DIMENSIONS (mm) MODEL X Y R1 R2 R3 R4 Total LENGTH WIDTH HEIGHT 16-i 946 943 65 73 114 129 380 1880 1534 637 19 09.18 207733 Rev.103
INSTALLATION EWCIBA DIMENSIONS AND WEIGHT Models 20-i 25-i EWCIBA CENTRE OF GRAVITY (cm) WEIGHT DISTRIBUTION (kg) DIMENSIONS (mm) MODEL X Y R1 R2 R3 R4 Total LENGTH WIDTH HEIGHT 20-i 886 1056 83 82 125 123 414 1880 1810 675 25-i 892 1078 85 85 135 134 439 1880 1810 675 20 09.18 207733 Rev.103
INSTALLATION DIMENSIONS More information in the user manual of each indoor unit. FK ZEN-OCT models 62 / 65 FK ZEN BIG-OCT 72 model 21 09.18 207733 Rev.103
INSTALLATION DIMENSIONS FCCW-OCT models FCCW Dimensions Distance Between Slots Main Coil Model H L S C D G N Y A B I 30 480 1260 225 970 995 233 39 109 274 137 10 60 585 1460 225 1170 1195 253 41 107 268 253 12 80 607 1660 257 1335 1362 - - - - - 14 110 607 1960 257 1635 1662 - - - - - 17 Grills 22 09.18 207733 Rev.103
INSTALLATION DIMENSIONS FCW-OCT models FCW Dimensions Distance Between Slots Main Coil Candensates Drainage Model H L S C D G N Y A B I O 30 460 1020 220 970 995 233 39 109 274 137 115 352 60 565 1220 220 1170 1195 253 41 107 268 253 99 402 23 09.18 207733 Rev.103
INSTALLATION DIMENSIONS FCW and FCCW connections CONNEXIONS MODELS FCW-OCT (Horizontal) FCCW-OCT (Vertical with cabinet) 30 60 30 60 80 110 Direct battery Inlet/Outlet (1) Ø" - 3/4" 3/4" 3/4" 3/4" 3/4" 3/4" Water Inlet/Outlet (equip. w/tubes (2) Ø" - 1/2" 1/2" 1/2" 1/2" 3/4" 1" (1) Drawing of the water connexions of the FCW and FCCW models: Expansion device+valve+copper tubes (Standard 3R battery). (2) 24 09.18 207733 Rev.103
INSTALLATION DIMENSIONS BSW-OCT models DIMENSIONS MODEL 2 3 5 Fittings (male) L mm 1070 1270 1520 H mm 297 347 397 P mm 643 643 770 A mm 956 1156 1406 B mm 253 303 353 M mm 980 1180 1430 C mm 247 297 347 D mm 237 237 300,5 E mm 118 118 195 F mm 93,5 118,5 143,5 G mm 233 233 310 I mm 83,5 108,5 133,5 N mm 193 193 270 2 rows coil Ø 1/2 3/4 1 4 rows coil Ø 3/4 3/4 1 6 rows coil Ø 3/4 1 1 1/4 Net weight kg 38 49 72 25 09.18 207733 Rev.103
INSTALLATION INSTALLATION LOCATION Consult and respect the rules and local regulations which regulate the installation of air conditioning systems. Choose a site without dust and debris. Respect the appropriate service area for the equipment which will be installed. Verify that the ground or structure on which the unit will be installed is able to support its weight in operation. Fit shock absorbers throughout the installation to prevent the transmission of noise and vibration. Check that the direction of the sound level is not going to disturb anyone. UNIT SETTLEMENT On Floor To ensure the level, transmission of noise and / or vibrations it is advisable to place the equipment on a bench. It must have the robustness and the adequate surface to hold and distribute the weight of the unit and allow the use of air ducts in the case that the air inlet and / or outlet is lower. Ensure drains work properly. The use of shock absorbers is recommended to avoid transmission of noise and vibrations. Suspended from the Ceiling Suspend the unit as shown in the drawing. Ensure that the roof can withstand the weight of the unit, which is indicated on the rating plate. Prevent any part of the Machine from touching the Ceiling, leaving a minimum space between them. CENTRAL UNIT OCTOPLUS On floor or suspended from ceiling Use threaded rod of M10. All rods must be positioned and with the same tension before unloading the full weight of the machine. Do not use anti-vibration or mounting springs ATTACHED to the machine, but to the ceiling. 26 09.18 207733 Rev.103
INSTALLATION UNIT SETTLEMENT INDOOR UNIT FCCW-OCT Wall Mounting INDOOR UNIT FCW-OCT Suspended from Ceiling 27 09.18 207733 Rev.103
INSTALLATION UNIT SETTLEMENT INDOOR UNIT FKZEN OCT Suspended from ceiling Suspend the unit as shown in the drawing. Ensure that the roof can withstand the weight of the unit, which is indicated on the rating plate. Prevent any part of the machine from touching the ceiling, leaving a minimum space between them. Secure the panel to the correct position so that the panel connectors can be connected to the unit. INDOOR UNIT BSW OCT Suspended from ceiling 28 09.18 207733 Rev.103
INSTALLATION SERVICE AREA (OCTOPLUS) For proper access to service and maintenance tasks, it is necessary to leave the following service areas around the machine free. Note: If the minimum maintenance levels cannot be met or there are obstacles, check the feasibility with Hitecsa. Model 16-i Models 20-i 25-i 29 09.18 207733 Rev.103
INSTALLATION WATER DRAIN General Recommendations The diameter of the drain line should be equal or bigger than the unit connection diameter depending on length and building configuration. The drainage line should be inclined a minimum 2% for proper water evacuation. It is convenient to install the drain trap with proper dimensions (see drawing). Recommended drain trap measures When drain line is exposed to air temperatures below 0 degrees, it is necessary to cover with thermal insulation or electrical heating wire to avoid water freezing and tube damage. Drained water can sometimes freeze and / or produce moss, etc. To avoid slipping, avoid draining to crowded areas. In any case always follow the local regulations. It is recommended to use a drain trap in each outlet to facilitate evacuation, but it is not guaranteed that all the condensates are drained. Central Unit OCTOPLUS Drainage The drain is supplied by a 3/4 "gas connection. Tilt the machine to facilitate drainage. Avoid free draining of the machine, unless you are sure that it will not cause any discomfort On Floor Suspended from Ceiling > 20mm < 25mm Drainage Tube < 25mm > 20mm (11mm/m) Drainage Tube To improve the drainage of the condensate it is necessary to request the optional external condensate tray with electric heater (optional low outdoor temperature). 30 09.18 207733 Rev.103
INSTALLATION WATER DRAIN Indoor Units Drainage FK ZEN-OCT The drainage is made by connecting to a 13.5 mm pipe. It includes a condensate pump that allows you to save a height of 200 mm max. To ensure a correct water flow, the drainage pipe must have a slope of 3%, unobstructed. Install a siphon of 50 mm minimum depth to avoid unpleasant odors. FCW-OCT / FCCW-OCT / BSW-OCT By gravity, follow the general recommendations. BSW-OCT: The condensate pump can be ordered as an option. Main Supply: 230V 50 Hz 18W Max Flow Rate: 20 l/h Maximum Suction Height: 2 m Height of the Maximum Output: 6 m FCW-OCT: The condensate pump can be ordered as an option. Main Supply: 230v 50 Hz 18W Max Flow Rate: 8 l/h Maximum Suction Height: 1 m Height of the Maximum Output: 6 m AIR DUCTS The dimensions of the ducts will be determined according to the air flow rate and the available static pressure of the unit. The ducts will be designed by qualified technical personnel. Use ducts made of non-flammable materials that do not emit toxic gases in case of fire. It is advisable to use insulated sheet metal ducts. For connecting the air duct to the unit, use a flexible part to avoid transmitting vibrations and noise. 16-i 20-i 25-i DIMENSIONS Outlet Inlet Cent. EC Inlet Outlet Inlet Outlet Height mm 500 350 500 525 525 525 525 Width mm 645 400 645 825 440 825 440 31 09.18 207733 Rev.103
INSTALLATION WATER PIPELINES Preliminary Information The selection and installation of the components of the installation must be carried out by a qualified installer, respecting the current legislation at the place of the work and rules of good practice. The design and calculation of pipes shall be carried out in such a way that the pressure drop of the installation never exceeds that which can overcome the pump built into the unit. In addition, a poor design of the pressure drop of the branch pipes that go to the indoor units can cause the malfunction of some of them. Components Shut-off valve Installed in the inlet and the outlet of each component, they allow to carry out the maintenance operations without having to empty the installation. Thermometers and pressure gauges Installed in the inlet and the outlet of the main elements. Facilitate maintenance and control operations. Traps Installed at the highest points of the installation. Allow air purging of the circuit. Drainage valve Install them in all the low points of the circuit to allow their emptying. Supports The weight of the pipes must not be supported by the connections of the unit, therefore flexible elements that prevent it will be installed. Expansion vessel Maintains the correct pressure of the installation, we recommend filling to 2.15 bar, when the water temperature varies from cold to pump and vice versa. The expansion vessel has to be dimensioned according to the water content of the installation. In special circumstances it may be necessary to install one or more additional glasses even if the unit is equipped with it. Security elements Installation of the following safety features, when NOT included in the unit, is MANDATORY. Failure to do so will cause LOSS OF WARRANTY. Water filter At the water inlet of the unit to protect the heat exchanger or other critical components from blockages and / or plugging. Flow switch or differential pressure switch Protection of the water exchanger against breakage due to insufficient water flow, which can lead to total disabling of the equipment. The EWCIBA central unit has a differential pressure switch as standard. It is mandatory to install the flow switch to the water outlet of the machine with a straight horizontal section of 6Ø inlet and outlet of 5Ø horizontal length without section changes to ensure that the water/liquid flow regime is laminar. In case of placing flow switches not supplied by HITECSA, follow the manufacturer's instructions, as long as the lengths mentioned above are not reduced. This safety components must be checked and adjusted, if necessary, after the installation of the equipment. Risk of Frost If the unit or the corresponding water connection are subjected to temperatures close to 4ºC take the appropriate measures to prevent the risk of frost. For example: Mix the water of the installation with glycol. Protect pipes with heating cables placed under insulation. Empty the installation by checking that: There are no closed valves that can retain water even after emptying. There are no low spots where water can become stagnant even after emptying; if necessary make a blown. 32 07.18 207733 Rev.102.b
INSTALLATION WATER PIPELINES Glycol Additions Keep in mind that the use of glycol solutions increases the pressure drop. Ensure that the type of glycol used is compatible with hydraulic circuit components (pumps, filters, etc.) and non-corrosive. Hydraulic Connections The Octoplus units are supplied with Victaulic type joints. Make the connection between the installation pipe and the evaporator through the joint. Optionally, a grooved pipe adapter with male gas thread is supplied. ELECTRICAL INSTALLATION CENTRAL UNIT WARNING! Disconnect the main power switch before any intervention. The power supply of the unit must be within 10% of the voltage indicated on the rated plate. Damage caused by starting the unit in an incorrect voltage line is not covered by Hitecsa's warranty. Always use the electrical diagram of the unit to make the connections. It must be checked that the crankcase heater is started before starting the unit. The installer must place line protection elements in accordance with current legislation. The wiring of electrical interconnections must be protected by a tube or a cable duct. Electrical Data ELECTRICAL SPECIFICATIONS MODELS 16-i 20-i 25-i Power Supply V / ~ / Hz 400 / 3+N / 50 Maximum Current A 21,2 25,8 31,2 Starting Current (AC) A Soft Start Differential Switch ma 300 300 300 Connection to Main Switch (Terminal) mm² 1,5 a 16,0 Select the section of the connection cables according to the voltage drop limitations indicated in the REBT: ITC-BT-19 section 2.2.2. (Spanish legislation). If the unit is installed in another country, the current legislation of this country must be complied. Ensure a good ground connection (according to current legislation). Due to the presence of frequency converters in this unit, we recommend the use of differentials with protection against harmonics (super immunized). 33 07.18 207733 Rev.102.b
INSTALLATION ELECTRICAL INSTALLATION CENTRAL UNIT Electrical Diagram (OCTOPLUS) See indoor units diagrams. 1. Air Outlet (Access) 2. Emergency Shutdown 3. Water Inlet 4. Power Cables Entry 5. Water Outlet 6. Drainage 7. Optional EC Air Outlet, Access Power: (No. of diagram: 201313-01-E1) 34 07.18 207733 Rev.102.b
INSTALLATION ELECTRICAL INSTALLATION CENTRAL UNIT Electrical Diagram (OCTOPLUS) Manoeuvre and control: (No. of diagram: 201313-02-E1) Legend: (No. of diagram: 201313-02-E1) 35 07.18 207733 Rev.102.b
INSTALLATION ELECTRICAL INSTALLATION CENTRAL UNIT Controller The standard control screen for the user is the Mini-pGD display (pgd1 optional). The screen is connected via 6-wire telephone cable to the (μpc) board of the central unit. For lengths greater than 50m and less than 200m it is recommended to use two TCONN units interspersed by shielded cable of 2 twisted pairs of conductors. Configuration of the internal MODBUS network The central unit communicates with all indoor units via an RS485 / Modbus network (see figure). The wiring is via two twisted and shielded conductors (we recommend AWG 20/22 type TC and the screens which are in contact with a drain wire). All units (8 maximum) must be connected one after the other forming a communications bus. From the pgd indicator screen, we can configure and display almost all network parameters. The central unit is factory-set: the controller is the Master and the power + (inverter compressor controller) has the address No. 2 of the network. INSTALLATION AND CONFIGURATION OF INDOOR UNITS Configuration of Indoor Units in the Network The electronic boards of the indoor units come with two blocks of 8 DIP switches each, one block is the one of configuration and the other one of address in the Modbus network. The board configuration switches are correctly set by default, except when an element that does not come as standard is installed. The configuration of the master indoor unit will be made during the configuration of the OCTOPLUS system, therefore, the DIP 8 will always be left OFF. (See User Manuals for indoor units). Indoor Unit Board In the cassette units, the DIP No. 3 is set to OFF (Remote control) and the other units are set to ON (Wall Thermostat). Turn DIP 3 ON if the cassette is installed with a wall thermostat. Thermostat Board The thermostat also has 6 DIP switches that must be set when we install it in a cassette: DIPs No. 2 and No. 3 ON in standard configuration for 2-pipe systems, DIP No. 4 will be OFF when the thermostat uses its own temperature probe (default), and "ON" when using another external temperature probe (in the cassette, etc.). 36 07.18 207733 Rev.102.b
INSTALLATION INSTALLATION AND CONFIGURATION OF INDOOR UNIT Configuration of Indoor Units in the Network The last connected indoor unit must close the communications bus, this action will be done by a jumper on the electronic board of said unit: Indoor Units Type BUS Situation Jumper Action Addressing Indoor Units Cassette Floor / Centrifugal Intermediate Final (Last Unit) Intermediate Final (Last Unit) JP2 Opened JP2 Closed JP1 Opened JP1 Closed ASSIGNMENT OF MODBUS ADDRESSES BY TYPE OF INDOOR UNITS 1 2 3 4 5 6 7 8 ADDRESS 1 1 0 0 0 0 0 0 3 (Cassette nº1) 0 0 1 0 0 0 0 0 4 (Cassette nº2) 1 0 1 0 0 0 0 0 5 (Cassette nº3) 0 1 1 0 0 0 0 0 6 (Cassette nº4) 1 1 1 0 0 0 0 0 7 (Centrifugal nº1) 0 0 0 1 0 0 0 0 8 (Centrifugal nº2) 1 0 0 1 0 0 0 0 9 (Centrifugal nº3) 0 1 0 1 0 0 0 0 10 (Centrifugal nº4) 1 1 0 1 0 0 0 0 11 (Cassette nº5) 0 0 1 1 0 0 0 0 12 (Cassette nº6) 1 0 1 1 0 0 0 0 13 (Cassette nº7) 0 1 1 1 0 0 0 0 14 (Cassette nº8) 1 1 1 1 0 0 0 0 15 (Centrifugal nº5) 0 0 0 0 1 0 0 0 16 (Centrifugal nº6) 1 0 0 0 1 0 0 0 17 (Centrifugal nº7) 0 1 0 0 1 0 0 0 18 (Centrifugal nº8) The network address of the units will depend on the type of indoor unit: Indoor Units CASSETTE TYPE (FK ZEN-OCT and FK ZEN BIG-OCT): The addresses will be chosen, in order, from the following numbers: 3, 4, 5, 6, 11, 12, 13 and 14. Indoor Units ON FLOOR and / or DUCT SYSTEM: The addresses will be distributed in order 7, 8, 9, 10, 15, 16, 17, 18. To configure the address, on the board, in the set of "ADDRESS" switches move the DIPs according to the table above. Connection between Indoor Units and the Thermostat 37 07.18 207733 Rev.102.b
INSTALLATION CONFIGURATION OF INDOOR UNITS IN THE OCTOPLUS SYSTEM Access the service menu using the PRG key and the UP and DOWN keys. Access the Service Parameters menu. Access the Thermoregulation menu. POWER OF THE UNITS Press (DOWN) to get to the screen Gfc02 where we will indicate how many units we have and what powers and type. Power = 0 unit disabled. Power > 0 unit enabled. All units other than the cassette type will be set as "CEN" We can configure up to 8 units. MASTER UNIT In the second screen we will select which unit is the master. Although the status change mode is not Master, we must select a unit as master in case that mode is selected at any time. Power offset is an increase to the power of the indoor units to overcome installation losses, it should be left at 7% by default. MINIMUM FLOW Press until the indicated screen ("Water pump") is displayed. We must put the indoor unit with less power on, we will set the minimum output to 0% (corresponds to the minimum pump frequency: 15Hz). Flow Switch alarm (IF) must be activated (IF: Yes), if it is not, set it until you disconnect (IF: Yes). The differential pressure switch (PDA) must also be in alarm (PDA: Yes), otherwise contact the technical support service. Raise pump output (from 5% to 5%) until all safety features are off ("No"). This value + an additional 5% will be configured as the minimum output of the pump. MAXIMUM FLOW All indoor units must be put into operation until the compressor runs at 100% (See OPERATION / THERMOSTAT AND CONTROL). We are located in the previous screen and raise the output of the pump until the indicated water flow is equal to the nominal flow rate of the unit, If we do not have a water flow meter we will raise the output until the temperature drop is equal to or around 5ºC. The value obtained will be configured as the maximum output value of the pump. 38 WARNING! The total sum of the powers of the indoor units must not exceed 120% of the rated cooling capacity of the central unit. If the water pressure drop is too low, it could be possible that the water flow was sufficient (greater than 1m 3 ) even with minimum output 0%. In this case, close a shut-off valve to check that the safety features work properly. 07.18 207733 Rev.102.b
INSTALLATION REFRIGERATION DIAGRAMS Models from 16-i to 25-i 1 - Compressor 2-4-Way Valve 3 - Electronic Expansion Valve 4 - One-Way Valve 5 - Filter 6 - Liquid Receiver 7 - Plates Exchanger 8 - Suction Accumulator 9 - Outdoor Centrifugal Fan 10 - Condenser Coil B1 - Circulating Pump FM - Water Flow Meter HP - High Pressure Switch HPS - High Pressure Probe LPS - Low Pressure Probe PD - Differential pressure switch TD - Discharge Temperature TE - Outdoor Temperature TS - Suction Temperature TEA - Water Inlet Temperature TSA - Water Outlet Temperature VEx - Expansion Vessel VS - Solenoid Valve ACCESSORIES FS - Flow Switch (Inserted in a 500mm tube with Victaulic connection) FT - Filtro de agua FM - Water flow gauge VB - Solenoid Valve (Bypass) 39 07.18 207733 Rev.102.b
OPERATION START UP Start-up has to be performed by a qualified service personnel. Check that all panels are firmly secured with screws. Check that there is no leakage of oil or refrigerant. Ensure that the unit is evenly levelled. Check if there is enough space for operation and maintenance. ELECTRIC SYSTEM Before opening the electrical panel and having access to the inside of the machine it is MANDATORY to disconnect the power supply hose of the machine which MUST BE FREE OF VOLTAGE for this operation. Always use the electrical diagram of the unit to make the connections. Make sure that all electrical connections are properly tight. The power supply of the unit must be as indicated on the serial plate. Damage caused by the start-up of the unit in an incorrect voltage line is not covered by Hitecsa's warranty. The unit must not be supplied with any voltage other than that indicated on the serial plate. The power supply to the unit must be within 5% of the voltage indicated on the serial plate. The installer must place line protection elements in accordance with current legislation. Wiring of electrical connections must be protected by a tube or other cable conduits. Make sure if the crankcase heater of each compressor has been operating for 24 hours prior the Start Up. HYDRONIC SYSTEM Carry out a thorough wash of the installation with clean water: filling and discharging the installation several times. Apply additives to avoid corrosion, incrustation forming, mud and algae. Filling the installation. Check that the drain is not blocked. Perform a hydraulic pressure test to check for leaks. Isolate all pipes to prevent heat loss and condensation. Leave free the different services points. Note: Neglecting cleaning of the hydraulic circuit, it will force a series of interventions to clean the filter and worse, it can damage the heat exchangers, produce frostbite and damage other components. VENTILATION SYSTEM Check the direction of fans rotation. Check the condition and placement of grilles, diffusers, air ducts, tarpaulins, etc. It is necessary to take notes of the air inlet and outlet temperatures to the external coil, the volts and amps of the compressor and motor fan, as well as the suction and discharge pressure of the compressor. Check that the air filters are clean and correctly fitted. It should be remembered that it is necessary to clean the air filters after the first 4 hours of operation. Observe at least, 3 cooling cycle operations. Due to the unit has frequency converters, it is essential that the protection be at least 300mA to prevent power cuts caused by the activation of the circuit breaker. 40 07.18 207733 Rev.102.b
OPERATION OUTDOOR FAN TRANSMISSION ADJUSTMENT (Only for FANS with PULLEY TRANSMISSION) Adjust transmission in such a way that indoor motor consumption comes to nominal value. If consumption is below nominal value it means unit air flow is too low. To change fan speed: 1. Remove the belt. Move the motor along its track (or loosen the tensor set screw) in order to release it. 2. Loose the set screws of the motor pulley and turn the movable flange. Open or close depending on the needs (Open: speed decreases). 3. Tighten set screws. 4. Place the belt in the pulley cannel. The closure or opening of the pulley could void the size of the prior belt. In this case, replace it for other belt of the same profile and with the appropriate length. 5. Tighten the belt by using tensor screw or sliding the motor, depending on the case. 1. Motor 2. Motor pulley 3. Transmission belt 4. Fan pulley 5. Tensor set screw 6. Set screw 7. Fixed flange 8. Movable flange 1. To align fan and motor pulleys: 1. Loose fan pulley set screw. 2. Slide fan pulley along the shaft and align with motor using a ruler. Make sure that is parallel to the belt. 3. Tighten fan pulley setscrews. CORRECT RULER POSITION WRONG WRONG ALIGNEMENT WRONG To adjust the belt tension: 1. Loosen the rods on the motor mounting plate and slide it. 2. The flexibility of the belt is calculated in mm, dividing the S value by 40. S(mm) +/- 2 F (mm) +/- 1 S(mm) +/- 2 F (mm) +/- 1 200-250 5,0-6,2 425-450 10,6 11,2 250-300 6,2-7,5 450-475 11,2 11,8 300-325 7,5-8,1 475-500 11,8 12,5 325-350 8,1-8,7 500-525 12,5 13,1 350-375 8,7-9,4 525-550 13,1 13,7 375-400 9,4-10,0 550-655 13,7 16,2 400-425 10,0-10,6 655-750 16,2 18,7 41 07.18 207733 Rev.102.b
OPERATION OPERATING LIMITS Heating Mode Refrigeration Mode TEMPERATURE COOLING MINIMUM MAXIMUM Cold Water Outlet 5ºC* 18ºC Outdoor Air (Dry Bulb) -12ºC 50ºC HEATING MINIMUM MAXIMUM Hot Water Outlet 25ºC 55ºC Outdoor Air (Wet Bulb) -13ºC 24ºC Water Flow 1 m 3 /h Rated * For lower temperatures it is necessary to use the water mixture with glycol. This unit can operate up to a maximum altitude of 1500 m, with an efficiency loss of less than 3%. For higher altitudes or other operating conditions consult. 42 07.18 207733 Rev.102.b
OPERATION THERMOSTAT AND CONTROL Mini-pGD or pgd1 Thermostat Once the machine is configured and commissioned, the user can manage the installation using the thermostats or controls of each indoor unit or from the Mini pgd screen located on the machine. In the main screen of the pgd we will see the information of the equipment. 1. Compressor speed in %. 2. Pump state. 3. Reserved zone for notifications like (defrost, etc.). 4. External fan speed. 5. System status: ON - Some of the indoor units are running. OFF-HOR - System stopped by chiller schedule. OFF-DIN - System stopped by the external stop / start. OFF-TECL - None of the indoor units are running. OFF-AL - System stopped by some severe alarm. 6. Water inlet and outlet temperature. 7. Operation Mode (depends on indoor units). 8. Indication of regulation probe of the chiller. Management of Indoor Units By pressing the DOWN key from the main screen we can access the control screens of the indoor units that we have configured. Pressing UP and DOWN will move through all the screens of the indoor units. To return to the main screen press ESC. 1. Ambient temperature read by indoor unit 2. Water temperature read by indoor unit 3. Operation mode, can be modified with pgd or user control. 4. Fan speed, can be modified with pgd or user control. 5. Setpoint, can be modified with pgd or user control. 6. On/off, can be modified with pgd or user control. 7. The word MASTER will appear on the selected unit as such. Severe Alarm Reset When the main display shows OFF-AL means that we have a severe alarm that has stopped the machine, either temporarily or permanently. Depending on the type of alarm (see alarm table), the machine will restart automatically when the alarm condition disappears. If the alarm is manual reset, to reset it we must press the button twice: or If the alarm is not active the operating mode will return to its normal state, either OFF or ON. 43 07.18 207733 Rev.102.b
OPERATION THERMOSTAT AND CONTROL Operating Mode Setting The operating mode of the Main Chiller Unit is selected according to the operation mode of the Indoor Units, but we have several options. This type of operation will be selected in the menu: SERVICE password Service Parameters Thermoregulation On the first screen, you can select the operating mode depending on the purchased system. 44 07.18 207733 Rev.102.b
OPERATION THERMOSTAT AND CONTROL Operating Mode Setting CONFIGURATION OPERATING MODE CENTRAL UNIT INDOOR UNIT OPERATING LOGIC STANDARD MASTER NORMAL STANDARD STANDARD STANDARD BE VERSION BR VERSION STANDARD BE VERSION BR VERSION An IU-OCT defined as Master selects the operating mode (cooling or heating). If the other IU-OCT require another different service mode, they can provide heat (BE version) or only ventilation. A weight is assigned to each indoor unit. If the majority group requests cooling, the outdoor unit runs in cooling. If the minority requests heating at the same time, heating with electric heater is provided (BE version). COMFORT EFFICIENCY MASTER STANDARD BE VERSION NORMAL STANDARD BE VERSION COMFORT STANDARD BE VERSION MASTER STANDARD BR VERSION NORMAL STANDARD BR VERSION ECO STANDARD BR VERSION A defined IU-OCT selects the operating mode (cooling or heating). If the other IU-OCT require a different service mode, they can provide heat or ventilation. A weight is assigned to each indoor unit. If the majority group requests cooling, the outdoor unit gets cold. If the minority requests heating at the same time, heating with electric heater will be provided. When any unit requests cooling, the OU-OCT will run in cooling and the rest of the units will provide heating with electric heater. A defined IU selects the operating mode (cooling or heating). If the other IU-OCT require another different service mode they will be able to use the ventilation mode. A weight is assigned to each indoor unit. If the majority group requests cooling, the outdoor unit runs in cooling. The same as NORMAL mode but the compressor is running at its optimal efficiency point, as well as the fan speed selection. 45 07.18 207733 Rev.102.b
OPERATION THERMOSTAT AND CONTROL Alarms OCTOPLUS Unit All alarms displayed on the thermostat, except those that have a WARNING category, will cause the stop of the unit. Cancellation of the alarm or Description of the Alarm Codes This button lights up (in pgd1 only) if the unit has an active alarm, pressing the button the acoustic alarm is removed, after a second press if the alarm is solved the alarm will be cleared. In case of not being solved, call the technical service. Alarm message Reset Relay Description Possible Cause Alarms Clock card error or not connected Alarms B02 probe broken or disconnected Alarms B03 probe broken or disconnected Alarms B05 probe broken or disconnected Alarms B10 probe broken or disconnected Manual Auto Auto Auto Auto Yes Yes Yes Yes Yes Alarms Insufficient flow meter Auto Yes Alarms Compressor start failed Auto 5 r. Yes Error on the clock card of the main board Alarm water inlet probe broken or disconnected Alarm water outlet probe broken or disconnected Alarm outdoor temperature probe broken or disconnected Alarm flow meter broken or disconnected Alarm outdoor temperature probe broken or disconnected Compressor blocked or without enough differential pressure at start-up - Need to change battery - Main electronic board damaged - Disconnected probe - Damaged probe - Main electronic board damaged - Disconnected probe - Damaged probe - Main electronic board damaged - Disconnected probe - Damaged probe - Main electronic board damaged - Disconnected flow meter - Damaged flow meter - Main electronic board damaged - Pipping obstruction Set value too high - flow meter broken - Main electronic board damaged - Refrigerant leak - Compressor blocked Alarms Envelope Zone: Auto 5 r. Yes Compressor out of its work area - Extreme conditions - Installation problem Alarms High temperature on the gas discharge Alarms Low differential pressure (Low lubrication) Alarms Inverter model is not compatible Manual Yes Discharge temperature out of the compressor limits - Refrigerant leak Yes Low differential pressure - Refrigerant leak Yes Non-matching power+ model with compressor model - Communication error between main electronic board and power+ (wiring cut or power+ voltage failure) Alarms Power+ nß Offline Device Manual Yes No connection with Power+ Wiring error or voltage loss of the power+ Alarms Power+ Over current Auto Yes Alarms Power+ Over current Alarms Power+ Motor overload Manual Yes Alarms Power+ Motor overload Alarms Power+ Overvoltage Auto Yes Alarms Power+ Overvoltage Alarms Power+ Under voltage Auto Yes Alarms Power+ Under voltage Alarms Power+ Drive over temperature Alarms Power+ Drive under temperature Alarms Power+ Overcurrent Hardware Alarms Power+ Motor over temperature Manual Yes Alarms Power+ Drive over temperature Manual Yes Alarms Power+ Drive under temperature Auto Yes Alarms Power+ Overcurrent Hardware Manual Yes Alarms Power+ Motor over temperature Alarms Power+ CPU error Manual Yes Alarms Power+ CPU error Loss of data in memory Alarms Power+ DCbus ripple Auto Yes Alarms Power+ DCbus ripple Phase failure at input The drive has detected a generated current too high by: Unforeseen heavy load increase; Acceleration too high; The current generated has exceeded the nominal motor current beyond the maximum allowed time. The DC intermediate circuit voltage has exceeded the limits set by: Deceleration too high High overvoltage spikes in the supply network The DC intermediate circuit voltage is below the limits set by: Insufficient power supply voltage Drive internal fault The drive temperature has exceeded the maximum allowed level. The drive temperature is below the minimum allowed level. The drive has detected an instantaneous current generated too high by: Unpredicted heavy load increase; Short circuit of the motor cables; The temperature detected by the PTC thermistor corresponds to a resistance > 2.600ohm 46 07.18 207733 Rev.102.b
OPERATION THERMOSTAT AND CONTROL Alarms OCTOPLUS Unit Alarm message Reset Relay Description Possible Cause Alarms Power+ Data communication fault Alarms Power+ Damaged internal thermistor Auto Manual Yes Yes Alarms Power+ Drive disabled Manual Yes Alarms Power+ Data communication fault Alarms Power+ Damaged internal thermistor Safety pressure switch activated (42Bar) Problem with the wiring or the Power+ voltage Internal malfunction - In cold (lack of air flow) - In pump (lack of water flow) Alarms Power+ Motor phase fault Auto Yes Alarms Power+ Motor phase fault Motor cable disconnected Alarms Power+ Seized motor Auto Yes Alarms Power+ Seized motor Inadequate motor load Alarms Power+ PFC module error Manual Yes Alarms Power+ PFC module error Overcurrent in PFC circuit Alarms Power+ Power supply overvoltage Alarms Power+ Power supply under voltage Alarms Power+ STO error detection Auto Manual Yes Yes Alarms Power+ Power supply overvoltage Alarms Power+ Power supply under voltage Excessive AC voltage input. Insufficient AC voltage input. Manual Yes Alarms Power+ STO error detection Internal malfunction Alarms Power+ Ground fault Manual Yes Alarms Power+ Ground fault The drive has detected a leakage current to ground too high Alarms Power+ CPU sync error 1 Manual Yes Alarms Power+ CPU sync error 1 CPU Overload Alarms Power+ CPU sync error 2 Manual Yes Alarms Power+ CPU sync error 2 Loss of data in memory Alarms Power+ Drive overload Auto Yes Alarms Power+ Drive overload The current generated has exceeded the nominal motor current beyond the maximum allowed time. Alarms Power+ Unexpected start Manual Yes Alarms Power+ Unexpected start Sync error Alarms Power+ Unexpected stop Auto Yes Alarms Power+ Unexpected stop Sync error Light high pressure Auto 5 r. Yes High pressure transducer - In cold (lack of air flow) - In pump (lack of water flow) Severe high pressure Manual Yes High pressure transducer (5 in 1 hour) - In cold (lack of air flow) - In pump (lack of water flow) Light low pressure Auto 5 r. Yes Low pressure transducer - In cold (lack of water flow) - In pump (lack of air flow) Severe low pressure Manual Yes Low pressure transducer (5 in 1 hour) - In cold (lack of water flow) - In pump (lack of air flow) Alarms End defrost for maximum time Alarms Probe S1: Probe S2: Probe S3: Probe S4: Auto No Defrost finished by time not by pressure - Environmental conditions out of limits Auto Yes Alarm overheating probe broken or disconnected - Disconnected probe - Damaged probe - Main electronic board damaged Alarms Low Superheat (LowSH) Auto Yes Superheating below the limit - Wrong probe readings - Alarms Low evaporation temperature (LOP) Alarms High evaporation temperature (MOP) Alarms High condensing temperature (HiTCond) Auto Yes Evaporation temperature below the limit Auto Yes Evaporation temperature above the limit Auto Yes Condensation temperature above the limit Alarms Low suction temperature Auto Yes Suction temperature below the limit 47 07.18 207733 Rev.102.b
OPERATION THERMOSTAT AND CONTROL Alarms OCTOPLUS Unit Alarm message Reset Relay Description Possible Cause Alarm Refrigerant leak Yes Low refrigerant level Alarms B01 probe broken or disconnected Alarms B07 probe broken or disconnected Auto Auto Yes Yes Alarm Discharge temperature of the compressor probe broken or disconnected Alarm High pressure probe broken or disconnected Alarm water pump 1 thermal switch Auto Yes Alarm Water pump thermal switch Ice alarm Yes Alarm Low temperature probe water impulsion - Low outdoor temperature - Low water flow Alarm Flow switch Yes Flow fault (flow switch) - Error in water circuit - Fault in water pump Offline Fancoil 1 Auto Yes Communication error Fancoil 1 - Communication bus problem - Voltage fault in Fancoil 1 Offline Fancoil 2 Auto Yes Communication error Fancoil 2 - Communication bus problem - Voltage fault in Fancoil 2 Offline Fancoil 3 Auto Yes Communication error Fancoil 3 - Communication bus problem - Voltage fault in Fancoil 3 Offline Fancoil 4 Auto Yes Communication error Fancoil 4 - Communication bus problem - Voltage fault in Fancoil 4 Offline Fancoil 5 Auto Yes Communication error Fancoil 5 - Communication bus problem - Voltage fault in Fancoil 5 Offline Fancoil 6 Auto Yes Communication error Fancoil 6 - Communication bus problem - Voltage fault in Fancoil 6 Offline Fancoil 7 Auto Yes Communication error Fancoil 7 - Communication bus problem - Voltage fault in Fancoil 7 Offline Fancoil 8 Auto Yes Communication error Fancoil 8 - Communication bus problem - Voltage fault in Fancoil 8 Offline Fancoil 1 Centrifugal Auto Yes Offline Fancoil 2 Centrifugal Auto Yes Offline Fancoil 3 Centrifugal Auto Yes Offline Fancoil 4 Centrifugal Auto Yes Offline Fancoil 5 Centrifugal Auto Yes Offline Fancoil 6 Centrifugal Auto Yes Offline Fancoil 7 Centrifugal Auto Yes Offline Fancoil 8 Centrifugal Auto Yes Communication error Centrifugal Fancoil 1 Communication error Centrifugal Fancoil 2 Communication error Centrifugal Fancoil 3 Communication error Centrifugal Fancoil 4 Communication error Centrifugal Fancoil 5 Communication error Centrifugal Fancoil 6 Communication error Centrifugal Fancoil 7 Communication error Centrifugal Fancoil 8 - Communication bus problem - Voltage fault in Centrifugal Fancoil 1 - Communication bus problem - Voltage fault in Centrifugal Fancoil 2 - Communication bus problem - Voltage fault in Centrifugal Fancoil 3 - Communication bus problem - Voltage fault in Centrifugal Fancoil 4 - Communication bus problem - Voltage fault in Centrifugal Fancoil 5 - Communication bus problem - Voltage fault in Centrifugal Fancoil 6 - Communication bus problem - Voltage fault in Centrifugal Fancoil 7 - Communication bus problem - Voltage fault in Centrifugal Fancoil 8 Outdoor fan thermal switch Auto Yes Alarm outdoor fan thermal switch PDA Alarm Auto Yes Flow Fault Differential Pressure Switch 48 07.18 207733 Rev.102.b
OPERATION INDOOR UNITS Alarms in FCW-OCT / FCCW-OCT / BSW-OCT Boards LED INDICATION DESCRIPTION RESULT AL1 FLASHING T1 AIR RETURN PROBE DISCONNECTED OR SHORT CIRCUITED ALL OUTPUTS OFF AL2 FLASHING DI1 M/P ACTIVATED (OPEN) ALL OUTPUTS OFF AL2 CONTINUOUS T2 DISCONNECTED OR SHORT CIRCUITED OPERATION MODE TO BE DEFINED BY USER AL3 FLASHING DI2 TAKEN SENSOR (ON) ALL OUTPUTS OFF AL3 CONTINUOUS T3 COIL SENSOR DISCONNECTED OR OPEN PROTECTION DISCHARGE OF COLD AIR IN HEATING DISABLED 49 07.18 207733 Rev.102.b
OPERATION INDOOR UNITS Alarms in CASSETTE Board NORMAL OPERATION Fixed blue LED Cooling Mode Fixed red LED Heating Mode Off LED Ventilation Mode ON-OFF Flashing blue LED Open window switch Blue and red LED flashing intermittently Stand-by: water temperature probe T2 with reading in progress ALARMS Flashing red LED Two blinks and a pause ALARM SWITCH input open Condensing water level alarm Flashing red LED Three blinks and a pause MOTOR FAULT input open EC motor running alarm Flashing red LED Four blinks and a pause T3 = 75ºC T3 = 4ºC Maximum or low temperature alarm Flashing red LED Five blinks and a pause T1 disconnected or short circuited Flashing red LED Six blinks and a pause T2 disconnected or short circuited Flashing red LED Seven blinks and a pause T3 disconnected or short circuited 50 07.18 207733 Rev.102.b
OPERATION EC MOTOR FANS: DIAGNOSIS / FAULTS Trouble shooting Type of error Possible cause Remedial measures Failure line voltage. Failure of one phase. Under or overvoltage. Check line voltage. Earth fault. Check motor connection and line voltage. Fan does not run (anymore) Fan will not start Short circuit winding. The thermal protection of the motor has triggered (motor is overheated) Impeller blocked or dirty Temperature too low for bearing grease. Air stream wrong direction (Motor turns in wrong direction at high speed) Replace fan. Check for free air passages; remove foreign bodies if necessary "Impeller blocked or dirty". Check temperature of supply air. Check voltage. Switch off power to the motor and secure against switching back on. Check safe isolation from supply. Remove safety grille. Remove foreign bodies or soiling. Remount the safety grille. Insert bearing with cold greasing. Check air stream. Behaviour in rotation by air current in reverse direction. Fan turns too slowly Impeller / blade scrapes / brushes. Active temperature management effective (Motor or electronics overheated). Fan turns too slowly When indicated clear foreign bodies / dirt from the fan. Check for free air passages; remove foreign bodies if necessary. "Impeller blocked or dirty". Check temperature of supply air. Check installation space (air speed overheat sink). Fan turns too slowly. Air flow too low Airways blocked Check for free air passages (supply/exhaust air vents, filters) Impeller blocked or dirty Pressure loss different to planned. Check fan selection. Vibrations Imbalance. No or wrong vibration dampers (only in radial) Check blades for damage, soiling or ice. Impeller blocked or dirty Install correct vibration dampers Bearing damaged / worn. Change bearings. Unusual noises Impeller / blade scrapes / brushes. Operation beyond stall point (for axial fans) Wrong overlap on nozzle ( for centrifugal fans) When indicated clear foreign bodies / dirt from the fan. Impeller blocked or dirty Check for free air passages (supply / exhaust air vents, filters) Observe the installation instructions. 51 07.18 207733 Rev.102.b
OPERATION EC MOTOR FANS: DIAGNOSIS / FAULTS Status Out with flash code LED Code Alarm relay K1* Cause (Explanation) OFF Open No line voltage ON Closed Normal operation without fault 1x Closed No enable = OFF 2x Closed Active temperature management 3x Open HALL-IC fault 4x Open Line failure (only for 3~ types) 5x Open Motor blocked 6x Open IGBT fault 7x Open DC under voltage 8x Open DC overvoltage 9x Closed IGBT cooling down period 11x Open Fault motor start 12x Open Line voltage too low 13x Open Line voltage too high 14x Open Error peak current 17x Open Temperature alarm * K1: function programmed by manufacturer: error message not reversed. Rotation caused by an air flow in false direction When the fan is stopped (no signal, no electrical supply, etc.), the control of the motor does not interfere if the fan rotates in wrong direction (due to, for example, an air flow). If you switch on the fan while it is rotating in the opposite direction, firstly the control will reduce the rotations in a controlled way until it reaches the 0 value (fan stop). Then, the control will make a restart in the correct rotation direction. The higher the number of turns in the opposite direction, the longer the control will need to reach the fan. In the event that the fan rotates strongly in the opposite direction, it is possible that the control could not start the fan in the proper rotation direction. 52 07.18 207733 Rev.102.b
MAINTENANCE POSITION OF THE ELEMENTS OF FKZEN-OCT The electrical box will always be located in the position closest to the LED. 1. Direction of the bafles 2. Air intake grill with filter 3. Electrical box 4. Anchoring brackets 5. LED 6. Water pipe side 7. Drainage 53 07.18 207733 Rev.102.b
MAINTENANCE CONSERVATION AND CLEANING WARNING! Before performing any service or maintenance operation it is mandatory to turn off the main power switch of the system to avoid any personal injuries. Locked it so that nobody other than a qualified technician can switch on electrical power. Before opening the electrical panel and having access to the inside of the machine it is MANDATORY to disconnect the power supply hose of the machine which MUST BE FREE OF VOLTAGE for this operation. Only authorized personnel previously trained and qualified may carry out maintenance operations. If the unit should be disassembled, protect hands with work gloves. It is advisable to do maintenance works every 1.000 operating hours as well as at the beginning of each cooling season. Compressor: Periodically check the lubricant level, presence of vibrations or noise, motor insulation. Coils: At least once a year, clean condenser coils with water and detergent, then dry with air at a low pressure. Never clean with wire brush. Fans: Check the direction of rotation of the fans. Examine the support of the fans. Check the operating status. Check the condition and tension of the transmission belt, at least twice the first month of operation, and then every 1000 hours of operation. The motors and fans do not need any additional lubrication. Drainage system: Verify condition and good operation of the drainage tray and the drain trap. Refrigeration circuit: Check for oil refrigerant leaks, noises or vibrations of the system. Take measurements of temperatures and pressures of components and record them on the maintenance form. Electrical circuit: Make sure that all electrical connections -wires, contactors and terminals- are properly tight. Record the readings for volts and amperes of each compressor and fan motor. Verify the starting current. Check the good operation of all relays, pressure switches and phase sequence relay of Scroll compressor. Water circuit: Check for water leaks as well as noise and vibrations of system elements. Record water pressure values at the inlet and outlet of the pump and other system elements. Check inlet and outlet temperature to the exchanger, check water flow, check safety systems. CLEANING THE AIR FILTER Some of these equipments are provided with air filter at the fan inlet. During normal operation, the filter traps impurities present in the air. The filter should be cleaned periodically to keep the filter characteristics and fan airflow unchanged. It is advisable to clean the filter at least once a month, performing the following operations: 1. Remove the filter. 2. Place the filter on a flat, dry surface; then vacuum the accumulated dust using a vacuum cleaner. 3. Wash the filter with water and detergent (not solvents). 4. Dry the filter in an airy place, avoid exposing it to the sun. 5. Reassemble the filter only after checking that it is dry. NOTE: Wash the filter at the beginning and at the end of each season. The filter can be removed from the top or from the side. 54 07.18 207733 Rev.102.b
MAINTENANCE WATER QUALITY Water quality must be checked by qualified personnel. The factors that shall be analyzed are: Salts, PH Biological load (algae, etc.) Suspended solids. Dissolved oxygen. Water with inadequate characteristics can cause: Increased pressure drop. Reducing energy efficiency. Increase of corrosion. MAINTENANCE WITH EC MOTOR FAN - Make use of fire protections in brazing operations. - It is advisable to schedule maintenance visits every 1.000 operating hours. - Allow maintenance work to be carried out by trained specialists only. - Wear safety shoes and gloves for handling! - Please observe the safety regulations and the worker s protection rules by all maintenance and service work (EN 50 110, IEC 364). - EC motor fan: Due to safety reasons it is not allowed to make interventions or modifications for your own in the unit. All scheduled modifications must be written approved by the manufacturer. Use only spare parts/ wear parts / original accessories of the manufacturer of the fans. These parts have been specially designed for the unit. If you use parts of other manufacturers, it is not guaranteed that they have been manufactured to resist loads that are presented or that meet the relevant safety requirements. Parts and special equipment not supplied by the manufacturer of the fans are not authorized by these manufacturers to be used in the equipment. EC MOTOR FAN MAINTENANCE AND REPAIRS Repairing works must be carried out by trained specialists only. Wear safety shoes and gloves for handling. Please observe the safety regulations and the protection rules of the worker by all maintenance and service work (EN 50 110, IEC 364). Before working on the fan, this must be disconnected from the power supply and secured against switching back on! Keep the airways of the fan free danger because of objects dropping out! No maintenance work at running fan! Depending on the application and the transfer medium the impeller has a natural wear. Deposits on the impeller can lead to imbalance and thus to damages (danger of endurance fracture). The impeller can disintegrate! There is risk that the impeller could break because of the massive corrosion in case of transporting the product in highly aggressive environment that could not be appropriate for it. The affected impellers for this type of corrosion have to be replaced immediately. Deposits on the motor, especially in the refrigerating wings and motor cavities, block an appropriate refrigeration causing a premature disconnection of the motor. Therefore they have to be removed on time (cleaning). Maintenance interval in accordance with the degree of contamination of the impeller! Check the fan in regular periods in respect of mechanical vibrations (recommended every 6 months). Keep in mind the limit values indicated on ISO 14694 and perform correction measures in case of exceeding them (e.g. posterior balance by trained specialists). Check the impeller, in particular weld-seams, for possible cracks. Repair, e.g. by welding is prohibited! The fan or motor is maintenance-free due to the use of ball bearings with life-long lubrication. At the end of the grease life (30-40.000h approx.) it is necessary to change the bearing. Please contact our Service Department in this case as for all other damage (e.g. to the coil or electronics). Bolted-on wheels and / or wings may only be replaced by authorized manufacturer staff. The manufacturer shall not be liable for damage caused through improper repair work. A Regular inspection is required and cleaning may be necessary to avoid the imbalance and obstruction of the condensation water evacuation openings due to dirt. 55 07.18 207733 Rev.102.b
MAINTENANCE EC MOTOR FAN CLEANING Danger due to electric current ATTENTION! Voltage supply for motor must be interrupted and secured against restoration! Clean the circulation area of the air fan. Attention! Do not use any aggressive, paint solvent cleaning agents when cleaning. Make sure that no water gets inside the motor and the electronics (e.g. by direct contact with seals of motor openings), observe protection class (IP). It is necessary to check the free flow of the condensation water evacuation openings (if there are any) that are appropriate for set up position. In case of improper cleaning work no guarantee is assumed regarding corrosion formation / paint adhesion for unpainted / painted fans. To avoid humidity accumulation in the motor, the fan must be operated at least for 1 hour at 80 to 100% of maximum speed before cleaning! After the cleaning process, the fan must be operated for 2 hours at 80 to 100% of maximum speed for drying purposes! LUBRICANT The compressors with R-410A refrigerant use synthetic polyol ether oil. Each compressor manufacturer has a specific oil for its product. The compressor or system should not remain open to atmosphere for more than 15 minutes. Ester type synthetic lubricants (POE Polyol Ester) having high solubility with R-410A are used. Since these types of oils are very hygroscopic, extra care should be taken in handling them than with conventional ones. Moreover, when these synthetic oils are mixed with minerals or alkyl benzenes, they deteriorate causing capillary blockage or breakdowns in the compressor. DO NOT MIX UNDER ANY CIRCUMSTANCES. 56 07.18 207733 Rev.102.b
MAINTENANCE REFRIGERANT CHARGE WARNING! Never use oxygen to pressurize system or purge lines for leak test. Oxygen reacts violently with oil, which can cause an explosion resulting in damage, personal injury or death. In case it is necessary to add or recover refrigerant, use an electronic scale that is suitably reinforced and prepared to withstand the handling of the refrigerant bottle. The charge must be made in LIQUID condition. The inlet of liquid refrigerant R-410A in the empty tubes causes temperatures below 0ºC until the internal pressure reaches 7 bars. WARNING! If it is necessary to make brazing operation, first fill the circuit with dry nitrogen. Burning refrigerant 410A results in toxic gas emissions. Leaks should be repaired immediately. Never overcharge the system. Never use compressor as vacuum pump. If leakage symptoms appear during the operation, it is necessary to leak test. To find small leaks, you will need a detector for HCF. If gas leak is detected is necessary to remove and recuperate complete refrigerant charge. Pressurize system with dry nitrogen. If leakage has been not detected break a vacuum, dehydrate and charge with refrigerant. DO NOT REINTRODUCE USED REFRIGERANT, SEND IT TO AN AUTHORIZED RECYCLING LOCATION. 57 07.18 207733 Rev.102.b
APPENDIX: SAFETY DATA R410A Refrigerant Data Safety Data: R-410A Toxicity Contact with Skin Contact with Eyes Low Liquid spatters can cause freeze burns. It is impossible skin absorption could result dangerous. It can be slightly irritating. Liquid has a degrease effect. Defrost with water the affected zones. Take off carefully contaminated clothing, since it could have been sticked on the skin in case of frostbite. Wash up affected zones plenty of lukewarm water. If irritations or blister formation occur, get medical attention. Vapours cause harmful effects. Liquid splashes can cause freeze burns. Immediately flush with an ophthalmic solution or with lukewarm clear water for at least 10 minutes. Seek medical attention as soon as possible. Ingestion Very unlikely - should something happen, it will cause frost burns. Do not induce vomiting. Only if the patient is conscious, wash out mouth with water and give some 250 ml of water to drink. Then, obtain medical attention. Inhalation R-410A: High concentration levels in the air can cause an anaesthetic effect, including loss of consciousness. Exposure to extremely elevated dosages can be unexpectedly lethal. There is risk of suffocation at higher concentrations due to the oxygen content reduction at the atmosphere. Remove victim to fresh air, keep it warm and at rest. Supplemental oxygen if it is necessary. If breathing has stopped or is laboured, give assisted respirations. In case of cardiac arrest apply severe assisted massage. Get medical attention immediately. Medical Attention Semiotics or support therapy is recommended. Cardiac sensitisation has been observed that, in the presence of circulating catecholamines such as adrenalin, may cause cardiac arrhythmia and accordingly, in case of exposure to high concentrations, cardiac arrest. Prolonged Exposure R-410A: a study on the effects of exposure to 50,000 ppm during the whole life of rats has identified the development of benign testicle tumour. This situation should therefore be negligible for personnel exposed to concentrations equal to or lower than professional levels. Occupational Exposure Limits Stability Conditions to Avoid R-410A: Recommended threshold: 1000 ppm v/v - 8 hours TWA. R-410A: no specific data. Do not use in the presence of high temperatures, flames, burning surfaces and excess humidity. Hazardous Reactions A violent reaction can be occurred by contact with sodium, potassium, barium and other alkaline metals. Incompatible substances: magnesium and more than 2% magnesium alloys. Hazardous Decomposition Products R410A: Halogen acids produced by thermal decomposition and hydrolysis. 58 07.18 207733 Rev.102.b
APPENDIX: SAFETY DATA R410A Refrigerant Data General Precautions Safety Data: R410A Do not inhale concentrated vapours. Their concentration in the atmosphere should not exceed the minimum pre-set values and should be maintained below the professional threshold. Being weightier than the air, the vapour concentrates on the bottom, in narrow areas. Therefore, the exhaust system must work at low level. Respiratory System Protection If you are in doubt about the concentration in the atmosphere, it is recommended to wear a respirator approved by an Accident Prevention Authority, of the independent or oxygen type. Storage Cylinders must be stored in a cool, dry and properly ventilated storage area away from heat, flames, corrosive chemicals, flumes, explosives and be otherwise protected from damage. Keep a temperature below 50 C. Protective Clothing Wear overalls, protective waterproof gloves and protective goggles or a mask. Accidental Release Measures It is important to wear protective clothing and a respirator. Stop the source of the leak, if you can do this without danger. Negligible leaks can be left evaporating under the sun, providing that the room is well ventilated. Considerable leaks: ventilate the room. Reduce the leak with sand, earth or other absorbing substances. Make sure that the liquid does is not channelled into gutters, sewers or pits where the vapours are likely to create a stuffy atmosphere. Disposal The best method is recovery and recycling. If this method is not practicable, dispose according to an approved procedure, which shall ensure the absorption and neutralization of acids and toxic agents. Fire Fighting Information R-410A: Not flammable in the atmosphere. Cylinders Cylinders, if exposed to fire, shall be cooled by water jets; otherwise, if heated, they may explode. Protective Fire Fighting Equipment In case of fire, wear an independent respirator and protective clothing. 59 07.18 207733 Rev.102.b
60 07.18 207733 Rev.102.b Subject to modifications without prior notice.